AGCO Perkins 1100C Series Bedienungsanleitung

ENGINE

SERVICE MANUAL

Perkins®

1100C Series Diesel Engine

Electronic Control System Tier II

G00908788

CALIFORNIA

Proposition 65 Warning

WARNING: Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other repro-

ductive harm.

WARNING: Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of California to cause

cancer, birth defects, and other reproductive harm. Wash hands after

handling.

TO OUR CUSTOMER:

Congratulations on your selection of an AGCO® Product. We believe

you have exercised excellent judgment in the purchase of your

AGCO® machine. We are most appreciative of your patronage.

Your Dealer has performed the pre-delivery service on your new

machine.

He will discuss with you the operating and maintenance instructions

given in this manual, and instruct you in the proper and varied applica-

tions of this machine. Call on him at any time when you have a

question or need equipment related to the use of your machine.

We recommend that you carefully read this entire manual before

operating the unit. Also, time spent in becoming fully acquainted with

it’s performance features, adjustments, and maintenance schedules

will be repaid in a long and satisfactory life of the product.

This equipment is covered by a written warranty which will be

provided to you by your AGCO® Dealer at time of purchase.

AGCO

reserves the right to make changes or add improvements to its products at any time without incurring

any obligation to make such changes to products manufactured previously.

AGCO

, or its dealers, accept no

responsibility for variations which may be evident in the actual specifications of its products and the statements

and descriptions contained in this publication.

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Table of Contents

Troubleshooting Section

Electronic Troubleshooting

System Overview .................................................... 5

Glossary ................................................................. 9

Electronic Service Tools ........................................ 12

Diagnostic Codes .................................................. 13

Indicator Lamps .................................................... 15

Replacing the ECM ............................................... 18

Self-Diagnostics .................................................... 19

Sensors and Electrical Connectors ....................... 20

Engine Wiring Information .................................... 26

Programming Parameters

Programming Parameters ..................................... 30

Factory Passwords ................................................ 30

Flash Programming .............................................. 30

System Configuration Parameters

System Configuration Parameters ........................ 32

Troubleshooting without a Diagnostic Code

Alternator Noise (Noisy Operation) ....................... 33

Alternator Will Not Charge (Charging Problem) .... 33

Battery .................................................................. 33

Can Not Reach Top Engine RPM ......................... 34

Coolant in Engine Oil ............................................ 36

Coolant Temperature Is Too High ......................... 37

ECM Will Not Accept Factory Passwords ............. 38

ECM Will Not Communicate with Other Systems or

Display Modules .................................................. 38

Electronic Service Tool Will Not Communicate with

ECM .................................................................... 38

Engine Cranks but Will Not Start .......................... 39

Engine Has Early Wear ........................................ 41

Engine Misfires, Runs Rough or Is Unstable ........ 41

Engine Oil in Cooling System ............................... 43

Engine Speed Does Not Change .......................... 44

Engine Stalls at Low RPM .................................... 45

Engine Vibration ................................................... 45

Engine Will Not Crank ........................................... 47

Excessive Black Smoke ........................................ 48

Excessive Engine Oil Consumption ...................... 49

Excessive Valve Lash ........................................... 50

Excessive White Smoke ....................................... 51

Intake Air Temperature Is Too High ....................... 52

Intermittent Engine Shutdown ............................... 53

Intermittent Low Power or Power Cutout ............... 54

Low Engine Oil Pressure ...................................... 56

Low Power/Poor or No Response to Throttle ........ 57

Mechanical Noise (Knock) in Engine .................... 59

Noise Coming from Cylinder ................................. 59

Poor Acceleration or Response ............................ 60

Troubleshooting with a Diagnostic Code

CID 0041 FMI 03 8v Sensor Power Supply, Voltage

More Than Normal .............................................. 62

CID 0041 FMI 04 8v Sensor Power Supply, Voltage

Less Than Normal ............................................... 62

CID 0091 FMI 02 Throttle Demand Sensor Erratic Or

Intermittent .......................................................... 62

CID 0091 FMI 03 Throttle Demand Sensor Open

Circuit Or Shorted High ....................................... 63

CID 0091 FMI 04 Throttle Demand Sensor Shorted

Low ..................................................................... 63

CID 0091 FMI 08 Throttle Demand Sensor Abnormal

Signal .................................................................. 64

CID 0091 FMI 12 Throttle Demand Sensor Out Of

Calibration ........................................................... 64

CID 0100 FMI 03 Engine Oil Pressure Sensor Open

Circuit Or Shorted High ....................................... 64

CID 0100 FMI 04 Engine Oil Pressure Sensor

Shorted Low ........................................................ 65

CID 0100 FMI 10 Engine Oil Pressure Sensor, Power

Supply Open Circuit ............................................ 65

CID 0102 FMI 03 Intake Manifold Pressure Sensor,

Open Circuit Or Shorted High ............................. 66

CID 0102 FMI 04 Intake Manifold Pressure Sensor

Shorted Low ........................................................ 66

CID 0102 FMI 10 Intake Manifold Pressure Sensor

Power Supply Open Circuit ................................. 67

CID 0105 FMI 03 Intake Manifold Temperature

Sensor Open Circuit Or Shorted High ................ 67

CID 0105 FMI 04 Intake Manifold Temperature

Sensor Shorted Low ........................................... 67

CID 0110 FMI 03 Engine Coolant Temperature

Sensor Open Circuit Or Shorted High ................ 68

CID 0110 FMI 04 Engine Coolant Temperature

Sensor Shorted Low ........................................... 68

CID 0174 FMI 02 Fuel Temperature Sensor Erratic,

Intermittent .......................................................... 69

CID 0247 FMI 09 J1939 Datalink, Abnormal

Update ................................................................ 69

CID 0253 FMI 02 Incorrect ECM Software ........... 69

CID 0262 FMI 03 5v Sensor Power Supply, Voltage

More Than Normal .............................................. 70

CID 0262 FMI 04 5v Sensor Power Supply, Voltage

Less Than Normal ............................................... 70

CID 0266 FMI 02 Incorrect Crank-without-inject

inputs .................................................................. 71

CID 0320 FMI 02 Speed And Timing Sensor

Intermittent Loss Of Signal .................................. 71

CID 0320 FMI 11 Speed And Timing Sensor Loss Of

Signal .................................................................. 71

CID 0342 FMI 02 Speed And Timing Sensor No.2

Intermittent Signal ............................................... 72

CID 0774 FMI 02 Throttle Demand Sensor No.2

Erratic Or Intermittent .......................................... 72

CID 0774 FMI 03 Throttle Demand Sensor No.2

Open Circuit Or Shorted High ............................. 73

CID 0774 FMI 04 Throttle Demand Sensor No.2

Shorted Low ........................................................ 73

CID 0774 FMI 08 Throttle Demand Sensor No.2

Abnormal Signal .................................................. 73

CID 0774 FMI 12 Throttle Demand Sensor No.2 Out

Of Calibration ...................................................... 74

CID 1627 FMI 03 Fuel Injection Pump Relay Did Not

Turn Off ............................................................... 74

CID 1684 FMI 00 Fuel Injection Pump, Fuel

Temperature More Than Normal ......................... 74

CID 1684 FMI 02 Fuel Injection Pump, Software

Failure ................................................................. 75

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Table of Contents

CID 1684 FMI 03 Fuel Injection Pump, Fuelling

Fault .................................................................... 75

CID 1684 FMI 04 Fuel Injection Pump, Supply

Voltage Fault ....................................................... 76

CID 1684 FMI 05 Fuel Injection Pump, Invalid Pulse

Width ................................................................... 76

CID 1684 FMI 07 Fuel Injection Pump, Mechanical

Fault .................................................................... 77

CID 1684 FMI 08 Fuel Injection Pump, Crankshaft

Reference Fault ................................................... 77

CID 1684 FMI 09 Fuel Injection Pump, CAN

Fault .................................................................... 78

CID 1684 FMI 10 Fuel Injection Pump, Fuel Shutoff

Signal Error ......................................................... 78

CID 1684 FMI 11 Fuel Injection Pump, Internal

Sensor Fault ........................................................ 79

CID 1684 FMI 12 Fuel Injection Pump, Device

Failure ................................................................. 80

CID 1684 FMI 14 Fuel Injection Pump, No

Communications ................................................. 80

CID 1743 FMI 02 Engine Speed Mode Selection

Switch State, Invalid State .................................. 81

CID 1894 FMI 02 Set Speed Control Disengage

Switch State, Invalid State .................................. 81

CID 1895 FMI 02 Set Speed Control Speed Toggle

Switch, Invalid State ............................................ 81

Troubleshooting with an Event Code

Event Codes ........................................................ 83

E015 High Engine Coolant Temperature Derate ... 83

E016 High Engine Coolant Temperature

Shutdown ............................................................ 83

E017 High Engine Coolant Temperature

Warning ............................................................... 83

E025 High Intake Air Temperature Derate ............ 84

E027 High Intake Air Temperature Warning ......... 84

E040 Low Engine Oil Pressure Shutdown ............ 85

E054 High Fuel Temperature Derate .................... 85

E056 High Fuel Temperature Warning .................. 86

E100 Low Engine Oil Pressure Warning ............... 87

E190 Engine Overspeed Warning ........................ 88

E442 Engine Failed to Stop with a No-Fuel

Command ........................................................... 88

E883 Engine Failed To Stop When Fuel Solenoid

Disengaged ......................................................... 89

Diagnostic Functional Tests

5 Volt Engine Pressure Sensor Supply Circuit -

Test ..................................................................... 90

Air Inlet Heater Circuit - Test ................................. 97

Analog Throttle Position Sensor Circuit - Test .... 102

CAN Data Link Circuit - Test ............................... 111

Data Link Circuit - Test ........................................ 116

Digital Throttle Position Sensor Circuit - Test ...... 124

Electrical Connectors - Inspect ........................... 133

Electrical Power Supply Circuit - Test ................. 144

Engine Oil Level Switch Circuit - Test ................. 149

Engine Pressure Sensor Open or Short Circuit -

Test ................................................................... 154

Engine Speed/Timing Sensor Circuit - Test ........ 161

Engine Temperature Sensor Open or Short Circuit -

Test ................................................................... 168

Fuel Injection Pump Circuit - Test ....................... 175

Indicator Lamp Circuit - Test ............................... 192

Mode Selection Circuit - Test .............................. 195

Set Speed Circuit - Test ...................................... 202

Throttle Switch Circuit - Test ............................... 210

Index Section

Index ................................................................... 219

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Troubleshooting Section

Electronic Troubleshooting

i01798100

System Overview

System Operation

The 1104 models RF, RH, RK and 1106 model

VK engines were designed for electronic control.

The engines include an Electronic Control Module

(ECM), a fuel injection pump that is electronically

controlled, and a collection of engine sensors. The

ECM controls the engine operating parameters

through the software within the ECM and the inputs

from the various sensors. The software contains

parameters that control the engine operation. The

parameters include all of the operating maps and

customer selected parameters.

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Troubleshooting Section

Electronic Controls

g00908788

Illustration 1

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Troubleshooting Section

g00954204

Illustration 2

The electronic system consists of the Electronic

Control Module (ECM), the engine sensors, and the

Machine Interface Connector (MIC). The ECM is the

computer. The personality module is the software

for the computer. The personality module contains

the operating maps. The operating maps define the

following characteristics of the engine:

•Horsepower

•Torque curves

•Engine speed (rpm)

Engine Governor

The electronic controls determine the injection

timing and the amount of fuel that is delivered to

the cylinders. These decisions are based on the

actual conditions and the desired conditions at any

given time.

The governor compares the desired engine speed

to the actual engine speed. The actual engine

speed is determined through the crankshaft position

sensor. If the desired engine speed is greater than

the actual engine speed, the governor injects more

fuel in order to increase engine speed.

Timing Considerations

Once the governor has determined the amount of

fuel that is required, the governor must determine

the timing of the fuel injection. Fuel injection timing

is determined by the ECM after considering input

from the following components:

•Engine coolant temperature sensor

•The sensor for the intake manifold air temperature

•The sensor for the intake manifold pressure

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Troubleshooting Section

At start-up, the ECM determines the top dead

center position of the number 1 cylinder from the

speed/timing sensor in the fuel injection pump.

The ECM decides when fuel injection should occur

relative to the top dead center position. The ECM

provides the signal to the fuel injection pump spill

valve which stops fuel flow to the low pressure side.

The ECM then forces fuel to flow to the fuel injector

nozzles at the desired time. The ECM adjusts timing

for the best engine performance, the best fuel

economy and the best control of exhaust emissions.

Actual timing cannot be viewed with an electronic

service tool. Also, the desired timing cannot be

viewed with an electronic service tool.

Fuel Injection

The personality module inside the ECM sets certain

limits on the amount of fuel that can be injected.

The FRC Limit is a limit that is based on intake

manifold air pressure and engine rpm. The FRC

Limit is used to control the air/fuel ratio in order to

control the engine’s exhaust emissions. When the

ECM senses a higher intake manifold air pressure,

the ECM increases the FRC Limit. A higher intake

manifold air pressure indicates that there is more air

in the cylinder. When the ECM increases the FRC

Limit, the ECM allows more fuel into the cylinder.

The Rated Fuel Limit is a limit that is based on the

power rating of the engine and on the engine rpm.

The Rated Fuel Limit enables the engine power and

torque outputs to conform to the power and torque

curves of a specific engine model.

These limits are in the personality module and these

limits cannot be changed.

Diagnostic Codes

When the ECM detects an engine problem, the ECM

generates a diagnostic code. Also, the ECM logs

the diagnostic code in order to indicate the time of

the problem’s occurrence. The ECM also logs the

number of occurrences of the problem. There are

two types of diagnostic fault codes. There are fault

codes and event codes.

Diagnostic Fault Codes

Diagnostic fault codes are provided in order to

indicate that an electrical problem or an electronic

problem has been detected by the ECM. In some

cases, the engine performance can be affected

when the condition that is causing the code exists.

More frequently, the operator cannot detect any

difference in the engine performance.

If the operator indicates that a performance problem

occurs, the diagnostic code may indicate the cause

of the problem. Use either a laptop computer or a

hand held diagnostic tool to access the diagnostic

codes. The problem should then be corrected.

If the operator does not indicate a problem with

the engine performance and a diagnostic code is

logged by the ECM. This situation indicates that

the ECM detected an abnormal engine condition,

but the abnormal condition did not affect engine

performance. In this situation, the system has no

faults except when either of the following conditions

exist:

•There are several occurrences of the diagnostic

code in a very short period of time.

•The ECM is indicating an active code at the

present time.

Diagnostic Event Codes

Diagnostic event codes are used to indicate that

some operational problem has been detected in

the engine by the ECM. This does not indicate an

electronic malfunction.

Programmable Parameters

Certain parameters that affect the engine operation

may be changed with electronic service tools.

The parameters are stored in the ECM, and the

parameters are protected from unauthorized

changes by passwords. These parameters are

System Configuration Parameters.

System Configuration Parameters are set at the

factory. System Configuration Parameters affect

emissions or power ratings within the engine.

Factory passwords must be obtained and factory

passwords must be used to change the System

Configuration Parameters.

Passwords

System Configuration Parameters are protected

by factory passwords. Factory passwords are

calculated on a computer system that is available

only to Perkins distributors. Since factory passwords

contain alphabetic characters, only an electronic

service tool may change System Configuration

Parameters. System Configuration Parameters affect

the power rating or the emissions.

Refer to Troubleshooting, “Programming Parameters”

and Troubleshooting, “Factory Passwords”.

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Troubleshooting Section

i01798101

Glossary

Active Diagnostic Code – An active diagnostic code

alerts the operator or the service technician that an

electronic system malfunction is currently present.

Refer to the term “Diagnostic Code”in this glossary.

Alternating Current (AC) – Alternating current is an

electric current that reverses direction at a regular

interval that is reoccurring.

Before Top Dead Center (BTC) – BTDC is the 180

degrees of crankshaft rotation before the piston

reaches the top dead center position in the normal

direction of rotation.

Boost Pressure (Engines that are turbocharged) –

The difference between the turbocharger outlet

pressure and atmospheric pressure is commonly

referred to as boost pressure. The sensor for the

intake manifold air pressure measures the amount

of boost.

Breakout Harness – The breakout harness is a

test harness that is designed to connect into the

engine harness. This connection allows a normal

circuit operation and the connection simultaneously

provides a Breakout T in order to measure the

signals.

Bypass Circuit – A bypass circuit is a circuit that is

used as a substitute circuit for an existing circuit. A

bypass circuit is typically used as a test circuit.

CAN Data Link – The CAN Data Link is a serial

communications port that is used for communication

with other microprocessor based devices. In this

application, the CAN Data Link connects the ECM

to the Electronic Fuel Injection Pump.

Code – Refer to “Diagnostic Code”or “Event Code”.

Cold Mode – Cold mode is a mode for cold starting

and for cold engine operation that includes timing

that is retarded and low idle that is raised. This

mode is used for engine protection, reduced smoke

emissions and faster warm up time.

Communication Adapter Tool – The communication

adapter provides a communication link between the

ECM and the Electronic Service Tool.

Component Identifier (CID) – The CID is a number

that identifies the specific component of the

electronic control system that has experienced a

diagnostic code.

Coolant Level Sensor – The coolant level sensor

detects the absence or presence of coolant at the

probe. The sensor then sends a signal to the ECM.

Coolant Temperature Sensor – The coolant

temperature sensor detects the engine coolant

temperature for cold mode operation and for Engine

Monitoring.

Data Link – The Data Link is a serial communication

port that is used for communication with other

microprocessor based devices.

Desired Engine Speed – The desired engine speed

is input to the electronic governor within the ECM.

The electronic governor uses the signal from the

throttle position sensor, the engine speed/timing

sensor, and other sensors in order to determine the

desired engine speed.

Diagnostic Code – A diagnostic code is sometimes

referred to as a fault code. These codes indicate an

electronic system malfunction.

Diagnostic Lamp – A diagnostic lamp is sometimes

called the check engine light. The diagnostic lamp

is used to warn the operator of the presence of an

active diagnostic code.

Digital Sensor Return – The common line (ground)

from the ECM is used as ground for the digital

sensors.

Digital Sensors – Digital sensors produce a pulse

width modulated signal. Digital sensors are supplied

with +8 VDC from the ECM.

Digital Sensor Supply – The +8 VDC supply from the

ECM is used in order to power the digital sensors.

Direct Current (DC) – Direct current is the type of

current that flows consistently in only one direction.

DT, DT Connector, or Deutsch DT – This is a type

of connector that is used on Perkins engines. The

connectors are manufactured by Deutsch.

Duty Cycle – Refer to “Pulse Width Modulation”.

Electronic Engine Control – The electronic engine

control is a complete electronic system. The

electronic engine control monitors the engine

operation under all conditions. The electronic

engine control also controls the engine operation

under all conditions.

Electronic Service Tool – The electronic service tool

allows a computer (PC) to communicate with the

ECM.

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Troubleshooting Section

Electronic Control Module (ECM) –The ECM is the

control computer of the engine. The ECM provides

power to the electronics. The ECM monitors data

that is input from the sensors of the engine. The

ECM acts as a governor in order to control the

speed and the power of the engine.

Engine Monitoring –Engine Monitoring is the part

of the electronic engine control that monitors the

sensors. This also warns the operator of detected

problems.

Engine Oil Pressure Sensor –The engine oil

pressure sensor measures engine oil pressure. The

sensor sends the signal to the ECM.

Engine Speed/Timing Sensor –The engine

speed/timing sensor provides a variable amplitude

and pulse width modulated signal to the ECM. The

ECM interprets this signal as the crankshaft position

and the engine speed.

Event Code –An event code may be activated in

order to indicate an abnormal engine operating

condition. These codes usually indicate a

mechanical problem instead of an electrical system

problem.

Failure Mode Identifier (FMI) –This identifier

indicates the type of failure that has been

experienced by the component. The FMI has

been adopted from the SAE practice of J1587

diagnostics.

Flash Programming –Flash programming is the

method of programming or updating an ECM with

an electronic service tool over the data link instead

of replacing components.

Fuel Ratio Control (FRC) –The FRC is a limit that is

based on the control of the ratio of the fuel to air.

The FRC is used for purposes of emission control.

When the ECM senses a higher intake manifold

air pressure (more air into the cylinder), the FRC

increases the FRC Limit (more fuel into the cylinder).

Fuel Temperature Sensor –The fuel temperature

sensor detects the fuel temperature. The ECM

monitors the fuel temperature and the ECM adjusts

the calculated fuel rate accordingly.

Full Load Setting (FLS) –The FLS is the number

that represents the fuel system adjustment. This

adjustment is made at the factory in order to fine

tune the fuel system. The correct value for this

parameter is stamped on the engine information

ratings plate. This parameter must be programmed.

Full Torque Setting (FTS) –The FTS is similar

to the full load setting. This parameter must be

programmed.

Harness –The harness is the bundle of wiring

(loom) that connects all components of the

electronic system.

Hertz (Hz) –Hertz is the measure of electrical

frequency in cycles per second.

Intake Manifold Air Temperature Sensor –The

intake manifold air temperature sensor detects the

air temperature in the intake manifold. The ECM

monitors the air temperature and other data in the

intake manifold in order to adjust injection timing

and other performance functions.

Intake Manifold Pressure Sensor –The air pressure

in the intake manifold may be different to the

air pressure outside the engine (atmospheric

pressure). This difference in air pressure can be

caused by variable air velocity within the manifold.

The difference in pressure can also be caused

by an increase in air pressure by a turbocharger

(if equipped). The sensor for the intake manifold

air pressure measures the difference between

atmospheric pressure and the air pressure in the

intake manifold.

Integrated Electronic Controls –The engine is

designed with the electronic controls as a necessary

part of the system. The engine will not operate

without the electronic controls.

J1939 CAN Data Link –This data link is a SAE

diagnostic communications data link that is used to

communicate between the ECM and the electronic

service tool.

Logged Diagnostic Codes –Logged diagnostic

codes are codes which are stored in the memory.

These codes are meant to be an indicator of

possible causes for intermittent problems. Refer to

the term “Diagnostic Code”in this glossary for more

information.

MAB –This is a Bosch acronym for the fuel shutoff

inside the “VPM30”Fuel Injection Pump. The MAB

is a signal wire from the ECM to the Fuel Injection

Pump.

Open Circuit –An open circuit is a condition that is

caused by an open switch, or by an electrical wire

or a connection that is broken. When this condition

exists, the signal or the supply voltage can no

longer reach the intended destination.

Parameter –A parameter is a value or a limit that

is programmable. This helps determine specific

characteristics or behaviors of the engine.

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